Flat wound coils

ABSTRACT

A flat wound coil is provided having a hollow rectangular plastic spool with a transverse flange at one end and a transverse head at the other end, said head having two spaced pockets receiving the coil ends and the ends of lead wires with the lead wires extending through passages in the head and an outer heat sealed shell enclosing the coil and pockets.

United States Patent 1 m1 3,7455% Simon [451 July 10, 1973 FLAT WOUND COILS 2,355,417 8/1924 336/208 W 1 Inventor Robert Simon, Windsor, 2153111? 21137? 362333.;1131331113311111111.17 452262 [73] Assignee: Union Electronics, Windsor, N.Y.

Primary ExaminerE. A. Goldberg [221 Flled' 1971 Attorney-Eugene F. Buell et al. [21] Appl. No.: 196,398

[57] ABSTRACT [52] US. Cl 336/192, l74/DlG. 8, 336/208,

336/209 A flat wound coil 15 provided having a hollow rectangu- 511 Int. Cl. l-l0lf 15/10 Plastic W with a transverse flange at one end and [58] Field at Search 336/198 208 192 a transverse head at the Other Said head having 336/209. 7 4/616 two spaced pockets receiving the coil ends and the ends of lead wires with the lead wires extending through pas- [56] References Cited sages in the head and an outer heat sealed shell enclos- UNITED STATES PATENTS and Pmkets' 744,650 11/1903 Varley 336/192 4 Claims, 3 Drawing Figures FLAT WOUND COILS This invention relates to flat wound coils and particularly to a flat wound coil of high pull strength at the leads.

There are large numbers of flat wound coils used in various applications in the electrical and electronics industries. These spools have in the past been wrapped on a generally rectangular hollow spool having a transverse flange at each end which contained the coils on the spool. The ends of the coil wire were left exposed and a wrapper placed over the wire coils, leads were fastened to the exposed coil wire ends and then a second wrapper was applied over the leads, usually for a distance between one half and two thirds of the length of the spool, in order to hold the leads and provide some pull strength for the leads. This arrangement has been less than satisfactory because the pull strength is quite variable and because the positioning of the leads has little flexibility.

The present invention provides a flat wound coil which eliminates these problems and makes it possible to have higher and uniform pull strengths coupled with flexibility of lead placement.

Preferably I provide a spool of rectangular hollow shape with a transverse flange at one end and a transverse heat at the other end, the head having a pair of spaced pockets with lead passages extending through the head into the pockets. The coil is wound on the spool between the flange and head with the two ends being placed in the two spaced pockets, lead wires are passed through the lead passages and soldered to the coil wire ends in the two pockets and the whole assembly is then placed in a sleeve and the sleeve heat sealed in place so as to seal the coil and pockets.

In the forgoing general description I have set out certain objects, purposes and advantages of my invention. Other objects, purposes and advantages of this inven' tion will be apparent from a consideration of the following description and the accompanying drawings in which:

FIG. 1 is an isometric view of a spool as used in my invention;

FIG. 2 is an isometric view of the spool of FIG. 1 with a coil wound thereon;

FIG. 3 is an isometric view of the finished sealed coil;

Referring to the drawings 1 have illustrated a spool body 10 having a generally rectangular through passage 11, a transverse flange 12 at one end and a transverse head 13 at the other end. The head 13 is provided with spaced pockets l4 and 15, each with lead wires holes 16 and 17 at a desired angle through the head. A coil wire 18 is wound on the spool body 10 between flange 12 and heat 13 with the starting end 18a soldered to lead wire 19 in pocket 14 with the lead wire extending through hole 16 and the end wire 18b soldered to lead wire 20 in pocket 15 with the lead wire extending through hole 17. An outer shell 21 is formed around the formed coil by heat forming to seal the coil as shown in FIG. 3.

In the foregoing specification I have illustrated and described certain presently preferred practices and embodiments of my invention, however, it will be understood that this invention may be otherwise embodied within the scope of the following claims.

I claim:

1. A flat wound coil comprising a spool of rectangular hollow shape, a transverse flange at one end of said spool, a transverse elongated rectangular head at the opposite end of said spool, said head having a pair of spaced pockets in one long side separated from the spool by a flange portion with lead passages extending through the head from the other long side into the pockets, and a wire coil wound on said spool between the flange and head having two ends, one entering each pocket and being attached to a lead therein.

2. A flat wound coil as claimed in claim 1, wherein the coil ends are fastened to lead wires in the pockets of said head.

3. A flat wound coil as claimed in claim 2, wherein the spool and head are enclosed within a heat sealed shell.

4. A spool for flat wound coils, comprising a hollow rectangular body, a transverse rectangular flange at one end and a transverse elongated rectangular head at the opposite end, said head having spaced pockets and a lead wire through passages therein for connection to the ends of a coil on said body. 

1. A flat wound coil comprising a spool of rectangular hollow shape, a transverse flange at one end of said spool, a transverse elongated rectangular head at the opposite end of said spool, said head having a pair of spaced pockets in one long side separated from the spool by a flange portion with lead passages extending through the head from the other long side into the pockets, and a wire coil wound on said spool between the flange and head having two ends, one entering each pocket and being attached to a lead therein.
 2. A flat wound coil as claimed in claim 1, wherein the coil ends are fastened to lead wires in the pockets of said head.
 3. A flat wound coil as claimed in claim 2, wherein the spool and head are enclosed within a heat sealed shell.
 4. A spool for flat wound coils, comprising a hollow rectangular body, a transverse rectangular flange at one end and a transverse elongated rectangular head at the opposite end, said head having spaced pockets and a lead wire through passages therein for connection to the ends of a coil on said body. 